U.S. patent application number 11/328618 was filed with the patent office on 2006-07-13 for in situ pipe repair controller and system.
Invention is credited to Kenton L. Knoppel, William Lepola.
Application Number | 20060151037 11/328618 |
Document ID | / |
Family ID | 36652037 |
Filed Date | 2006-07-13 |
United States Patent
Application |
20060151037 |
Kind Code |
A1 |
Lepola; William ; et
al. |
July 13, 2006 |
In situ pipe repair controller and system
Abstract
A control apparatus used in conjunction with tools and devices
such as electrical power supplies, fluid pumps and vacuums for in
situ repair of pipes. A method for controlling in situ repair of
pipe using electrical power sources, fluid and pressure sources and
flexible heat and inflation bladder installing thermal responsive
repair materials and applying the repair material to the interior
wall surface. The apparatus controls the inflation of the repair
tool inserted into a pipe and the amount and rate of fluid pressure
and maintenance of a selected pressure. The apparatus may also
control the evacuation of the fluid from the bladder of the repair
tool. The device controls the heating of the tool used in the
installation of the repair material. The invention also teaches a
method for controlled inflation and expansion of the bladder
carrying the repair material to the area of the pipe to be repaired
and heating the material at a rate and to a temperature to
facilitate optimum curing or installation of the thermally
responsive repair material. The invention also teaches the
detachment of the repair material and removal of the repair tool.
The method further includes the procedures necessary to complete
the installation of these materials.
Inventors: |
Lepola; William; (Magnolia,
TX) ; Knoppel; Kenton L.; (Houston, TX) |
Correspondence
Address: |
LAW OFFICE OF DAVID MCEWING
P.O. BOX 231324
HOUSTON
TX
77023
US
|
Family ID: |
36652037 |
Appl. No.: |
11/328618 |
Filed: |
January 10, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60642566 |
Jan 10, 2005 |
|
|
|
Current U.S.
Class: |
138/98 ; 138/97;
156/287; 264/269; 264/270; 405/150.1; 425/387.1 |
Current CPC
Class: |
F16L 55/1654 20130101;
F16L 2101/18 20130101; G21C 17/017 20130101; Y02E 30/30
20130101 |
Class at
Publication: |
138/098 ;
138/097; 425/387.1; 405/150.1; 156/287; 264/269; 264/270 |
International
Class: |
F16L 55/16 20060101
F16L055/16 |
Claims
1. An controller attachable to a fluid source, an electrical power
source and a repair device comprising a fluid controlling component
and an electrical power controlling component wherein the
controller controls fluid pressure and electrical power to an
inflatable and resistively heatable bladder of the repair
device.
2. The controller of claim 1 further comprising controls to a
winding mechanism.
3. The controller of claim 1 further comprising an SCR.
4. The controller of claim 1 further comprising a fluid input, a
fluid output, an electrical input and an electrical output.
5. The controller of claim 1 further comprising an SCR.
6. The controller of claim 1 further comprising a CPU.
7. A method for controlling installation of in situ pipe repair
material comprising: a. positioning a pipe repair material into a
pipe; b. using a fluid controlling component to increase fluid
pressure to press the repair material to the pipe wall; c. using an
electrical power controlling component to energize components for
resistively heating the repair material; d. using the electrical
power controlling component to stop resistive heating; and e. using
the fluid controlling component to reduce fluid pressure.
8. The method of claim 7 further comprising removing a repair
device from the pipe.
9. An in situ pipe repair system comprising a pipe repair device
and a controller.
10. The system of claim 9 further comprising a CPU.
11. The system of claim 9 further comprising a fluid pump.
12. The system of claim 11 wherein the fluid pump is an air
compressor.
13. The system of claim 9 further comprising a transformer.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of and priority to U.S.
Provisional Application No. 60/642,566 entitled "V-Pac Controller"
and filed Jan. 10, 2005.
BACKGROUND OF INVENTION
[0002] 1. Field of Invention
[0003] The present invention generally relates to a control
apparatus and method used in conjunction with pipe repair devices.
More specifically, the invention pertains to a control apparatus
and method permitting the installation of a repair material
controlled from a remote location using fluid pressure and
electrically resistive or impedance heating to deploy, form and
cure the repair material to the inside surface of a pipe.
[0004] 2. Description of Related Art
[0005] The invention pertains to the field of pipe or conduit
repair. An example is installing a lining to the interior surface
of a pipe. Heated water or steam is sometimes used as part of the
lining installation process. Resistive heating may also be
used.
BRIEF SUMMARY OF THE INVENTION
[0006] The invention pertains to an in situ pipe repair device
controller that is attachable to a fluid source, an electrical
power source and an in situ pipe repair device. The controller
subject of the invention comprises a fluid controlling component
and an electrical power controlling component wherein the
controller controls fluid pressure and electrical power to an
inflatable and resistively heatable bladder of the in situ pipe
repair device.
[0007] The features and advantages of the present invention will be
apparent from the following description taken in conjunction with
the accompanying drawings, which illustrate, by way of example, the
principles of the invention. The scope of the invention however, is
not limited to this description. Other benefits of the invention
will also become apparent to those skilled in the art and such
advantages and benefits are included within the scope of this
invention.
BRIEF SUMMARY OF DRAWINGS
[0008] FIG. 1 illustrates a perspective view of the control
apparatus of the invention.
[0009] FIG. 2 illustrates a front view of the control apparatus
showing individual controls comprising one embodiment of the
invention.
[0010] FIG. 3 is an electrical and fluid schematic depiction of the
components of the embodiment of the control apparatus shown in FIG.
2.
[0011] FIG. 4 is a cross sectional illustration of a repair device
within the interior of a pipe and the device comprising multiple
heating zones that can be controlled by the invention.
[0012] FIG. 5 illustrates another embodiment of the control panel
subject of the invention.
[0013] FIG. 5A illustrates a detail of the control panel showing
controls for electrically powered winding mechanisms that may be
used to pull a repair device through a pipe.
[0014] FIG. 6 illustrates the steps of loading and installation of
repair material using a bladder deployment canister device that can
be used with and controlled by the subject invention.
[0015] FIG. 7 illustrates the arrangement of the apparatus with the
repair device, fluid source and electrical power supply used in one
embodiment of the invention.
[0016] FIG. 7A illustrates a detail of a device within a pipe that
is controlled by the invention.
[0017] FIG. 8 illustrates the bladder device component and repair
material used with the deployment canister and the invention.
[0018] FIG. 8A illustrates a detail of the attachment of the open
bladder end to the canister.
[0019] FIG. 8B illustrates a cross sectional view of the canister
and rotatable spool (shown in phantom) used to convey and deploy
the bladder.
[0020] FIG. 8C illustrates a prior art canister repair device
showing control components placed on the canister housing.
[0021] FIG. 9 illustrates a perspective view of a spot repair
device used in conjunction with the invention.
[0022] FIG. 9A is a detailed illustrated of one end of the spot
repair device and the connecting components to the controller.
[0023] FIGS. 10A through 10E illustrate the steps of a repair
process controlled by the device of the invention.
[0024] The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate preferred
embodiments of the invention. These drawings, together with the
general description of the invention given above and the detailed
description of the preferred embodiments given below, serve to
explain the principles of the invention.
DETAILED DESCRIPTION OF INVENTION
[0025] While this invention is susceptible of embodiments in many
different forms, there is shown in the drawings and will herein be
described in detail preferred embodiments of the invention with the
understanding that the present disclosure is to be considered as an
exemplification of the principles of the invention and is not
intended to limit the broad aspect of the invention to the
embodiments illustrated. The above general description and the
following detailed description are merely illustrative of the
subject invention and additional modes, advantages and particulars
of this invention will be readily suggested to those skilled in the
art without departing from the spirit and scope of the
invention.
[0026] The present invention generally relates to a control
apparatus (hereinafter "controller") and method to be used in
conjunction with pipe repair tools and devices and ancillary
components such as electrical power supplies, fluid pumps, air
compressors and vacuum pumps. The controller may be part of a
system for in situ repair of a pipe or conduit (hereinafter "pipe")
by using electrical power sources, fluid and pressure sources and
one or more pipe repair devices having heatable and inflatable
components. The pipe repair tools or devices (hereinafter "repair
devices") may be used for installing thermal responsive repair
materials to the interior pipe wall surface. The controller may
control the movement of the repair device within the pipe. The
controller may control the inflation of the repair device by
controlling the amount and rate of fluid pressure and maintenance
of a selected pressure within the inflatable component. The
controller may also control the evacuation of the fluid from the
inflatable component (hereinafter "bladder") of the repair tool.
The controller can also control the heating of the repair device
used in the installation of the repair material. The controller may
also include the capability of controlling the deployment of a
bladder and the ancillary components at the interface or junction
of two pipes.
[0027] The invention also teaches a method for controlled inflation
and expansion of the bladder (a repair device or component of a
repair device) carrying the repair material to the area of the pipe
to be repaired. The method also teaches heating the material at a
rate and to a temperature to facilitate optimum curing or
installation of the thermally responsive repair material. The
invention also teaches the detachment of the repair material and
removal of the repair device. The method further includes the
procedures necessary to complete the installation of these
materials.
[0028] The invention teaches a controller used in conjunction with
various repair devices to accomplish in situ repair of pipes,
including but not limited to underground pipes such as storm water
and waste water pipes. The pipes can have a horizontal or vertical
orientation. For example, the controller can be used in the lining
of roof drain pipes. The invention can also be used in the repair
of pipe used in chemical or other product manufacture or refining.
The pipes can be of various materials, including but not limited to
metal, plastic and concrete. The controller can contain or be used
in conjunction with a CPU, data recorder, data or signal input
output components and displays or printer. It may also be used with
television cameras and monitors to facilitate the operator being
able to visually monitor the deployment, placement and installation
of the repair material into the pipe. The operator can also inspect
the completion of repair prior to removal of all tooling, thereby
avoiding the necessity of redeploying inspection devices.
[0029] It will be appreciated that in many instances, the location
for the pipe repair is of very limited accessibility. The pipes may
be of less than 6 inch diameter. The location for pipe repair can
be in hazardous, unhealthy or harsh environments. It is often
difficult to maneuver the repair material through the pipe to the
necessary location. It is desired to have the repair device placed
at an access port closest the repair location. This access location
is also often harsh, dangerous or otherwise unsuitable for the
device operator. It is therefore desirable that the operator of the
repair devices be able to control the repair operations from a
remote and less hazardous location. The can be accomplished by a
single unit controlling multiple devices, components and
operations.
[0030] FIG. 1 illustrates one embodiment of the in situ pipe repair
controller. The controller 600 is, in one embodiment, contained in
a portable case or container which can be attached to varying
components such as an electrical power supply (a power source), air
compressor (a fluid source), as well as the repair material
installation device (repair device), such as a spot repair bladder,
a lateral interface device or a bladder deployment canister (also
known as a portable pipe repair system with electrically heated
positioning member). The controller case is constructed of a
lightweight but resilient resin plastic. The case and control panel
may also include multiple "o-rings" or similar structures for
moisture protection.
[0031] With reference to FIG. 2, the controller subject of the
invention may comprise fluid controlling components, illustrated as
a male type air hose attachment fitting (fluid input) 601, and a
counter part female air hose attachment outlet (fluid output) 602;
a fluid pressure gauge 603 for measuring fluid, e.g., air in pounds
per square inch or equivalent; a fluid pressure control 604 and
pressure release valve 605. The fluid controlling components may be
utilized in conjunction with an inflatable bladder or inflatable
component of the in situ pipe repair device.
[0032] The controller may include electrical power controlling
components for one or more electrically powered winders or winches
that can be utilized in conjunction with tether components of the
pipe repair device. The tether components, controllably powered by
the controller, can be used to deploy or pull (by winding and
unwinding) the repair device and as shown in FIGS. 10A through
10E.
[0033] The electrical power controls may also include components
for controlling electrical current powering a resistive heating
component within the pipe repair device. In one embodiment, the
controller will include electrical control components that may
comprise a 240 volt electrical input 611, a 480 volt electrical
input 612, and an emergency power shut off switch 613. The
controller may include one or more motorized cooling fans (not
shown) and one or more vents 614, electrical power outlets 615,
616, circuit breakers 622, potentiometer 621, a timer 617 and
electrical power meter 618 such as an amp meter. The controller
also may also comprise a power on/off switch 619 and an electrical
power controller 620. The controller may also contain power
indicators (pilots) 623, 624 for each of the 240 volt and 480 volt
circuits. The controller may contain a thyristor or silicon
controlled rectifier (SCR). It may also include thermisters and
temperature gauges responsive to one or more thermocouples. (It
will be appreciated that the thermocouples can be located in the
repair material being installed inside the pipe or located with the
repair material installation device.) The controller may also
contain one or more temperature gauges. It may also contain one or
more circuit switches (not shown), permitting electrical power to
be alternatively directed to different heating circuits (heating
components) within a repair device or actual repair material. This
may be particularly advantageous in the repair of large diameter
pipes.
[0034] In one embodiment, the controller may be utilized in
conjunction with a programmable CPU or processing unit. For
example, the controls may respond to data inputs from a laptop
computer and the computer may record the time and temperature
profiles of the cure cycle. Accordingly, the controller may contain
a suitable data input component such as a USB port or fire wire
connection.
[0035] In another embodiment, the controller also incorporates
several operator safety features. These features include use of 120
VAC and 240 VAC power supplies, in conjunction with contacts and
relays, to reduce the voltage at the controls to 12 volts. The
operator is also protected from the high voltage power supply by a
ground fault circuit interrupter (not shown). An additional safety
component is the prominent emergency off switch. The time or hour
meter can be used for prompting routine maintenance. A timer may
also be used for tracking a heating cycle.
[0036] FIG. 3 illustrates an electrical and fluid schematic diagram
of one embodiment of the invention. Power regulation may be
achieved by a solid state SCR, allowing infinitely variable range
of voltage to be delivered to the repair device or repair material
("load"). Due to the heat generated by the SCR, the controller
includes two fans ("intake" and "exhaust"). The control function
can be implemented utilizing a potentiometer or the controller may
be configured to accept signals from a CPU or process controller
(not shown). The SCR can control an intra-cycle "off" period.
During this very short interval, an impedance measurement of the
heating circuit can be taken. This measurement can be correlated to
temperature.
[0037] As indicated, one embodiment of the controller includes the
ability to monitor or control the temperature during the repair
process. Monitoring can, of course, be combined with varying the
power level to accurately maintain a desired heat level at
differing sections or locations in conjunction to the repair
material and location within the pipe. The silicon controlled
rectifier (SCR) controls current flow from an electrical power
source to the resistive heating elements using switching
techniques. When the control signal is off, the SCR performs as an
open switch and prevents the current from flowing from the SCR to
the resistive heating elements. At this time, the impedance of the
heating elements can be measured to identify the level of heat
production. When the control signal is on, the SCR acts as a
unidirectional switch and current can flow to the resistive heating
elements in one direction. SCR power controls use three different
switching modes; on-off, phase angle and zero-fired. On-off
controls replicate the operation of an electro-mechanical contactor
or relay. Phase angle control replicates the operation of variable
transformers, providing variable control of the voltage impressed
on the load. Because SCRs can be switched on at any time during
each half cycle of the AC wave-form, the voltage to the resistive
heating elements is infinitely variable from zero to 100%. Phase
angle switching will be suitable and desired for control of the
heating process controlled by the invention.
[0038] The impedance measurement referred to above can be the means
for in-process temperature monitoring. A measuring system will be
employed to provide a feedback signal to the SCR power supply. The
conductive fibers present in the resistive heating elements have a
dual purpose. During the "on" cycle of the SCR, these fibers will
provide the heat necessary for processing. During the "off" cycle
of the SCR, these fibers will be utilized as sensing electrodes to
provide information back to the impedance measuring system, and in
turn, to the SCR.
[0039] A direct correlation exists between the conductivity of the
heating elements and temperature that enables an accurate depiction
of heat generation to be determined continuously throughout the
repair process. In this technique, data from the monitoring will be
used as input for statistical process control (SPC). Software can
be developed to identify the time at which critical points related
to a specific event occur. This in turn will provide feedback to a
component that will send a proportional signal to the SCR.
[0040] Temperature control and monitoring can also be achieved by
use of thermocouples in the repair device bladder or repair
material. The schematic includes a thermocouple read out and
thermocouple input. Of course, electrically conductive signal leads
will be needed between the controller and the thermocouple.
[0041] In the schematic illustrated in FIG. 3, the fluid pressure
control 604A (shown to be pressurized air) is manually controlled.
It will be appreciated that in other embodiments, the fluid
pressure can be electronically controlled, including a control
processor. This control can be integrated to the electrical heating
cycle. In another embodiment, the controller of the invention can
include a multiple pole switch to direct electric power to variable
independent heating zones of a tool. A cross sectional view of such
a bladder 102 having 4 heating zone components 261, 262, 263, 264
is illustrated in FIG. 4. A similar repair device is illustrated in
FIG. 7A. Also illustrated in FIG. 4 is the relationship of the
bladder to the interior of the pipe wall 185.
[0042] The schematic also illustrates the ability to control 480
volts of power. This may require use of a booster transformer pack,
preferably in an outdoor "weather proof" casing. This booster pack
650, depicted in FIG. 7, doubles the voltage with a resulting
decrease in amperage.
[0043] FIGS. 5 and 5A illustrate another embodiment of the
invention that can include motor controls 631, 632 for a spool or
winches (winding mechanisms) attached to tether components used in
the deployment or retraction of repair devices from the pipe
system.
[0044] FIG. 7 illustrates a system and the relationship of the
controller 600 within the system to the repair device 102, the
electrical power supply 270 and the fluid supply source 190. Also
illustrated is the electrical power cable 247 between the power
supply and the booster 650 and the fluid supply hose 191 between
the fluid supply and the controller, as well as the fluid hose 160
from the controller to the repair device. The electric cables 245A,
245B comprising both legs of the electric circuit created in the
repair device are also illustrated. FIG. 7 further illustrates the
tethers 302, 303 controlling movement of the repair device within
the pipe 185, along with winches 312, 313 and the power cables 322,
323 extending from the controller.
[0045] FIG. 7A provides a detail of an embodiment of the connective
components between the controller (not shown) and the repair device
102. Illustrated is a combined fluid hose 160 and electric cable
245 within a structure 246. Also illustrated are the two tethers
302, 303 at each end of the repair device, multiple heating
components or zones 261, 262, 263 and connective wires 243, 244.
Movement of the repair device within the pipe 185 is illustrated by
the vector arrows 930, 940.
[0046] The method and system of the invention teaches using the
controller with one or more repair devices that can convey repair
material through the pipe to the repair location. These devices may
also press the repair material to the inner pipe wall surface.
Often the repair material is then heated. The heat is used to cure
or mold the repair material to the pipe surface. These devices may
include but are not limited to a bladder deployment canister,
lateral interface devices, spot repair devices, as well as
associated fluid compression or pumping/hydraulic components,
hoses, electric cables and power supplies and fluid inflatable or
electrically heatable bladder components. Examples of these devices
or tools are described fully in pending application Ser. Nos.
10/182,889; 10/256,294; 10/174,188; and 11/313,170 which are
incorporated by reference herein.
[0047] In one embodiment of the method taught by the invention, the
control device is used in conjunction with a bladder deployment
canister, a power supply and air compressor. FIG. 8 illustrates the
electrical relationship between the bladder device component of the
deployment canister (a repair device) and the controller 600.
Illustrated is the electrical contact 712 of the canister housing
(not shown) proximate to the open end 710A of the inverted bladder
740. (The open end of the bladder is attached to the bladder
deployment port 710 of the canister as shown in FIG. 8B.) The
inflatable and heatable bladder comprises a heating component 760
and an inflation component 710. The repair material is also
illustrated 810. It will be appreciated that the repair material
will be on the outside surface of the everted bladder. Also
illustrated is the electrically connective subcomponent 713 at the
closed end of the bladder and electrical wires 733, 734 forming the
two legs of the electrical circuit with the heating component and
the controller.
[0048] FIG. 8A illustrates a detail of the attachment of the open
bladder end to the canister. The relationship of the bladder 740
and electrically conductive components of the canister 712, 733,
734, 770 with the controller 600 are again illustrated. Electrical
cables 245A, 245B from the controller are in electrical
communication with the electrical wires 733, 734 through the
connective component 770. Also illustrated is a circular clamp
device 748 holding the open end of the bladder to the bladder
deployment port 710. The wall of the canister 609 and an o-ring 749
forming part of the fluid sealable connection between the open
bladder end and the canister are also illustrated.
[0049] FIG. 8B illustrates a cross sectional view of an embodiment
of the canister 700 and rotatable spool 760 used to convey and
deploy the bladder through the bladder access port 710.
[0050] FIG. 8C illustrates a prior art view of the canister repair
device showing a controller mechanism 600A placed on the canister
housing. Illustrated are the fluid connecting components 601, 602
and an electrical connective component 771. The bladder deployment
canister may be positioned proximate to the pipe access port. It
will be appreciated that the controller of the invention permits
the operator to control the repair function at a location remote
from the pipe access.
[0051] The bladder deployment canister may provide storage,
transportation and deployment of a flexible, heatable and
inflatable bladder or repair material. The bladder component may
comprise a fluid inflatable bladder having a cylindrical shape that
is closed at one end and an open or closeable second end. The
bladder has an interior wall surface and an exterior wall surface.
The bladder incorporates electrically conductive material that,
when energized with electric current controlled via the controller,
can create impedance or resisitive heat (hereinafter "resistive
heating") and a sub-component to attach an elongated tether
sub-component on the inside bladder wall proximate to the closed
bladder end. The tether sub-component has a first end and a second
end. The second open end of the bladder can be sealably attached to
an opening on the canister component. (See FIGS. 8 through 8B.)
Some or all of these components may also be integral to the
installed repair materials. For example, the repair material may
contain the heating, inflation or temperature monitoring elements,
all of which are left in place after completion of the repair.
[0052] The canister component, like the bladder, may be fluid
sealable. The canister is not expandable and maintains a rigid or
fixed volume. The interior of the canister (hereinafter "annulus")
can be placed in fluid communication (via the controller) with an
external fluid pressure or fluid vacuum source. The canister
annulus contains a rotatable spool sub-component in communication
with a rotating control mechanism. (See FIGS. 6 and 8B.) The spool
also has a mechanism to attach the second tether end. Operation of
the spool and tether can be controlled by the controller. The
canister also contains an opening ("bladder deployment port")
dimensioned to allow the bladder to pass through to be spooled on
the spool or deployed out of the canister with fluid pressure. The
bladder can be pulled into the canister and spooled on the internal
spool and first spooling a portion of the tether (not shown), the
closed end of the bladder being inverted into the remainder of the
bladder by the pulling action of the spooling tether. In this
manner, the flexible bladder operates like a sock being turned
inside out. The canister opening also contains mechanisms for
sealably attaching the second open end of the bladder. It will be
appreciated that the bladder and canister are to be in fluid sealed
communication. The canister also contains an electrical power
sub-component to convey electrical current from a power source to
the electrically conductive material of the bladder.
[0053] In utilizing the controller, the operator can activate the
air compressor to pump air into the canister repair device, causing
the bladder to extend and evert out from the canister. The operator
may control the rate of inflation to achieve proper bladder
deployment. The operator, using the controller, may also release
the winding mechanism controlling the deployment/retraction tether.
It will be appreciated that the winding component may be used when
the deflated bladder is retracted into the deployment canister.
[0054] In one embodiment, when the operator has extended the
bladder out of a canister, repair material can be placed on the
exterior bladder surface. See FIG. 6, Steps 1 & 2.) The length
of the bladder deployed can be controlled via the controller
utilizing a gauge and the fluid regulator component.
[0055] The repair material can be flexible fibrous material
containing heat reactive resin or polymer, either thermal setting
or thermal plastic (hereinafter "resin"). The resin can be applied
after the material is placed on the bladder or the repair material
can be pre-impregnated.
[0056] Adjusting the motor controller (see FIG. 5A), the operator
may retract the bladder, now containing the repair material, into
the canister. FIG. 6, Step 3. The operator may decrease the fluid
pressure or completely deflate the bladder. This may be
accomplished by adjusting the fluid pressure controller that may,
in turn, activate a pressure release valve or a vacuum pump in
communication with the bladder and canister. In one embodiment, the
tool retraction step may incorporate use of a tether (not shown)
attached to the inside of the bladder and proximate to the closed
end. The invention can control the winding mechanism(s) that may be
attached to the tether, thereby allowing the operator to control
the retraction of the bladder and repair material into the
canister. It will be appreciated that the bladder can carry the
repair material to the selected location within the pipe.
[0057] The controller can be utilized in multiple ways. The
operational procedures as depicted in FIG. 6, Steps 1 through 7 can
be summarized as follows:
[0058] Step 1. Unroll or festoon pre-impregnated repair material in
preparation for loading into Canister. A staging area equal to the
length of the repair is needed. This "loading" procedure can be
performed off-site. Stable resin matrix allows up to 8 hours of
"out-time" in cool conditions.
[0059] Step 2. Attach electrical power supply and hook-up air
supply to controller and canister and set the fluid pressure
controls to create a positive pressure within the canister. By
increasing the fluid pressure and placing the motor controller in
"neutral" or "forward", the inflation heating bladder is everted
from the canister through the bladder access port and into the
repair material. The motor controller controls the spool within the
canister. The motor controller therefore can be used to control
speed and length of the bladder everted from the canister.
[0060] The operator can, from a safe location, increase the fluid
pressure to deploy or inflate the bladder or repair material. The
fluid pressure is increased within the fixed volume of the
canister. The increasing pressure will force the inverted bladder
proximate to the inversion hose end to push outward to create a
larger volume within the combined and fluid sealed canister and
bladder. Stated another way, the operator increases the internal
volume of the closed canister bladder system by increasing the
fluid pressure. This expansion can be facilitated by the controlled
release of the tether attached to the bladder and windable spool.
This will loosen the collapsed bladder and tether spooled around
the spindle.
[0061] Step 3. With bladder fully extended through the length of
repair material, set the motor controls to "reverse" and adjust the
fluid pressure controller to an "exhaust" setting or otherwise to a
negative pressure. This adjustment may automatically open a
pressure relief valve. In another embodiment, the exhaust setting
may activate a vacuum pump. In another embodiment, the end of the
repair material may be tucked into the reverting (inverting) face
of the bladder, and is pulled into the bladder as it is spooled
back into the canister. The-motor controller may also control the
rewinding of the tether and inverted bladder onto the spool. The
motor controller will be placed in "reverse".
[0062] Step 5. Position the bladder access port (or alternatively
the end of an inversion hose attached to the bladder access port)
at the pipe access port. Attach the electrical power supply and the
fluid supply as in Step 2.
[0063] The loading procedures (Step 2) may determine where the
repair material will actually begin to unfurl. In other words, the
location of loading the repair material on the deployed bladder in
Step 2 above may be varied. This can be especially useful when
inserting through clean-outs, tee's and wye's. In one embodiment,
the controller may include a footage counter (component to measure
the length of the bladder deployed from the canister). A
consumable, temperature sensor (in communication with the
controller) can also be inserted into the host pipe to provide
feedback to the power controls (not shown).
[0064] Step 5. Set the fluid pressure controls to create a positive
pressure in the canister sufficient to commence eversion. Eversion
speed may be controlled via adjustment of fluid pressure and
turning of the spool. In one embodiment, the motor controls
(positioned in "forward") may contain a variable speed component.
The operator, utilizing the controller, continues to maintain a
pressure level by addition of additional fluid volume in response
to the everting bladder.
[0065] Step 6 illustrates a continuation of this process, with the
repair material now on the outside surface of the bladder,
extending into the pipe. When the bladder and repair material are
deployed to a desired distance within the pipe, the operator can
stop the addition of additional fluid and stop the release of
additional lengths of tether, thereby holding the inflated bladder
at a stationary position within the pipe. A footage counter located
on the controller can indicate complete deployment of material on
the everting bladder.
[0066] The fluid pressure can be further increased to the deployed
segment of bladder inflate the bladder in a radial direction,
thereby pressing the bladder wall, with the repair material, to the
inside pipe wall surface.
[0067] In one embodiment, the controller may incorporate a CPU or
process controller. A display monitor and data recorder can also be
employed. In such an embodiment, the temperature sensor located
proximate to the repair material is connected to the controller and
a programmable electronic controller may implement the cure of the
repair material. Complete cure is indicated on the controller. It
will be appreciated that the controller (and operator) may be
positioned away from the pipe access port.
[0068] In the described and illustrated embodiment the operator may
energize the electrically conductive material (not shown) within
the bladder with electric current. This can be accomplished using
the power controller. This will create the resisitive heat that can
cure the heat responsive resin. The operator can control the rate
of heat increase and the amount of heat generated by utilizing the
potentiometer or power controller to regulate the amount of
electrical current.
[0069] The controller may monitor the temperature of the bladder or
repair material by various methods, including but not limited to
thermocouples within selected location on the bladder or by one or
more consumable thermocouples placed in the repair material and in
detachable communication with the control device. Utilizing the
controls, the temperature can be maintained for a selected time to
allow cure of a thermosetting resin within the repair material or
molding of thermoplastic resin impregnated repair material to the
interior of the pipe. The operator can adjust the current to also
control the rate of cool down. Upon completion of this cure process
or molding step, the power controller may be adjusted to zero or
"off" and the operator may commence the repair device removal
steps.
[0070] Step 7. With cure complete, set fluid controller to a
decreased pressure setting at least sufficient to reduce the
bladder diameter or to collapse the bladder. The spool can be
controllably rotated to rewind the tether and bladder, re-inverting
the heating inflation bladder back into canister. This can be
accomplished by setting the motor controller to "reverse". Step 7
illustrates the removal of the repair bladder device from the pipe.
The removal step is the same as illustrated in FIG. 6, Step 3, but
the pipe repair material, now cured, remains in a rigid or fixed
position pressed against the inner pipe wall surface.
[0071] Other in situ pipe repair devices that are-controlled by the
invention may not utilize a bladder deployed from a fluid sealed
canister. Such a device is the spot repair bladder illustrated in
FIGS. 9 and 9A. FIG. 9 illustrates a perspective view of a spot
repair device 102 used in conjunction with the invention. Included
in the illustration are the tethers 302, 303, the connective wires
243, 244 in communication with the heating element 260 disposed
within the bladder and combined into the electrical cable 245
connected to the controller (not shown). FIG. 9A is a detailed
illustration of one end of the spot repair device and the
connecting components to the controller. Included in the
illustration are the fluid conveying hose 160 and the electrical
cable 245 combined into a single subcomponent 246 communicating
with the controller. The electrical wires 243, 244 communicating
with the heating component and combined into the electrical cable
245 are also illustrated.
[0072] FIGS. 10A through 10E illustrate the steps of a repair
process utilizing the spot repair device controlled by the
controller of the invention. With reference to FIGS. 10A through
10E, this device 102 containing the repair material 550 may be
deployed into the pipe 185 by a tether 302 controlled by the
controller (not shown). The device may be pulled within the pipe to
the repair location by a winch or similar device. The winding
motion of the winch is controlled by a first motor controller. The
direction of movement is illustrated by vector arrow 930. When the
operator has positioned the bladder proximate to the repair
location 549, FIG. 10B, the operator can then utilize the fluid
pressure control components of the controller to inflate the
bladder, FIG. 10C, to press the repair material to the inner pipe
wall surface. This step can be accomplished by adjusting the fluid
pressure to a positive setting.
[0073] After adequate inflation is achieved (the operator being
able to monitor the fluid pressure using the fluid pressure gauge),
the operator is able to energize the heating component using the
power controller. The amount of heat can be monitored and
controlled by the operator utilizing the potentiometer or power
controller in conjunction with thermocouples or the SCR device and
impedance measurements. The duration of the heating can be measured
by the timer contained within the invention. In other embodiments,
the controller may incorporate a programmable CPU or process
controller to control the amount and duration of heat and fluid
pressure. A display monitor and data recorder can also be employed.
After the operator has determined that the repair material has
adequately been heated, for example, to affect a desired cure of a
thermosetting resin matrix of the repair material, the electrical
power can be reduced or turned off.
[0074] One step of the retraction process of the tool from the pipe
is the reduction of pressure within the bladder. This step can be
facilitated by creating a negative pressure by use of a vacuum pump
controlled by the controller. The deflation of the bladder is
important to the separation of the repair material from the outer
surface of the bladder. After the operator has sufficiently
deflated the bladder, FIG. 10D, the operator may then activate a
second winding motor attached to a tether 303 connected to the
bladder, thereby pulling the deflated bladder from the pipe. The
retraction is shown in FIG. 10E by vector arrow 940.
[0075] In another embodiment, the controller may be used in the
repair of the interface or connection of two pipes. The may be
accomplished utilizing the Lateral Interface Device (a repair
device) described in application Ser. No. 10/182,889.
[0076] While specific embodiments have been illustrated and
described, numerous modifications are possible without departing
from the spirit of the invention, and the scope of protection is
only limited by the scope of the accompanying claims.
* * * * *